Sintered Material, Ferrous Sintered Sliding Material, Producing Method of the Same, Sliding Member, Producing Method of the Same and Coupling Device

Abstract

The iron-based sintered sliding material comprises: a sintered structure which contains 10-50 wt. % copper and 1-15 wt. % carbon and has been formed by sintering a powder mixture obtained by mixing at least one of an Fe—Cu alloy powder containing copper in an amount which is the solid solubility or larger and is 5-50 wt. %, excluding 50 wt. %, and an Fe—Cu—C alloy powder containing copper in an amount which is the solid solubility or larger and is 5-50 wt. %, excluding 50 wt. %, and containing carbon in an amount of 0-5 wt. %, excluding 0 wt. %, with a graphite powder and at least one of a copper powder and a copper alloy powder; and graphite particles dispersed in the sintered sliding material in an amount of 1-14 wt. % or 3-50 vol. %.

1 . A No. 3 substance based sintered material containing a No. 1 substance and a No. 2 substance,
 wherein said sintered material has:   a sintered structure formed by sintering a mixed powder of a No. 3 substance based powder containing the No. 1 substance in an amount of a solid solubility limit or larger; and another powder comprising the No. 2 substance, and   particle comprising the No. 2 substance dispersed in the sintered material,   in which the No. 2 substance does not react with the No. 1 substance, and   the No. 3 substance reacts with each of the No. 1 and No. 2 substances.   
     
     
         2 . The sintered material according to  claim 1 ,
 said sintered structure is a liquid-phase sintered structure in which a liquid phase composed of the No. 1 substance mainly is generated and then sintered.   
     
     
         3 . A ferrous sintered sliding material containing copper in an amount of 5 to 50 wt % and C in an amount of 1 to 15 wt %,
 wherein said ferrous sintered sliding material has:   a sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %, and graphite powder; and   graphite particle dispersed in said sintered sliding material in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume.   
     
     
         4 . A ferrous sintered sliding material containing copper in an amount of 5 to 50 wt % and C in an amount of 1 to 15 wt %,
 wherein said ferrous sintered sliding material has:   a sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 2 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %; graphite powder; and at least one powder of copper powder and copper alloy powder; and   graphite particle dispersed in said sintered sliding material in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume.   
     
     
         5 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said sintered structure is a liquid-phase sintered structure in which copper alloy liquid phase composed of copper mainly is generated and then sintered.   
     
     
         6 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said graphite particle has an average grain size of 1 μm to 50 μm.   
     
     
         7 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said mixed powder further contains one or more powders selected from the group consisting of BN powder, Mo powder, W powder, Pb powder, MnS powder, TiS powder, CaF 2  powder, MoS 2  powder and WS 2  powder mixed therewith, and   said one or more powders and said graphite particles are dispersed in said sintered sliding material in a total amount of 1 wt % to 14 wt %.   
     
     
         8 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said mixed powder further contains at least one powder of MoS 2  powder and WS 2  powder, which is coated with carbonaceous material or graphite based material at a surface, mixed therein, and   said at least one powder and said graphite particles are dispersed in said sintered sliding material in a total amount of 1 wt % to 14 wt %.   
     
     
         9 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said Fe—Cu—C based alloy powder contains C in an amount of 1 wt % to 5 wt % and at least one of Si in an amount of 0.5 wt % to 7 wt % and Ni in an amount of 0.5 wt % to 7 wt %, and   said Fe—Cu—C based alloy powder has a ferrous alloy phase in which graphite is precipitated and dispersed.   
     
     
         10 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said ferrous alloy powder contains Al in an amount of 3 wt % to 20 wt %.   
     
     
         11 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said Fe—Cu—C based alloy powder contains C in an amount of 0.25 wt % to 3.5 wt % and one or more elements selected from the group consisting of Cr in an amount of 1 wt % to 25 wt %, Mo in an amount of larger than 0 wt % to 15 wt %, W in an amount of larger than 0 wt % to 21 wt % and V in an amount of larger than 0 wt % to 7 wt %, and   said Fe—Cu—C based alloy powder has one or more carbides selected from the group consisting of M 7 C 3  type carbide, M 6 C type carbide, M 2 C type carbide and MC type carbide precipitated and dispersed therein.   
     
     
         12 . The ferrous sintered sliding material according to  claim 3 ,
 wherein two or more alloy powders selected from the group consisting of the following alloy powders (1) to (5) are used, in place of said at least one ferrous alloy powder:   
       (1) Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt %; 
       (2) Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 2 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %; 
       (3) Fe—Cu—C based alloy powder containing C in an amount of 1 wt % to 5 wt % and at least one of Si in an amount of 0.5 wt % to 7 wt % or Ni in an amount of 0.5 wt % to 7 wt % and having graphite precipitated and dispersed therein; 
       (4) at least one ferrous alloy powder of Fe—Cu based alloy powder and Fe—Cu—C based alloy powder which contain Al in an amount of 3 wt % to 20 wt %; and 
       (5) Fe—Cu—C based alloy powder containing C in an amount of 0.25 wt % to 3.5 wt % and one or more elements selected from the group consisting of Cr in an amount of 1 wt % to 25 wt %, Mo in an amount of larger than 0 wt % to 15 wt %, W in an amount of larger than 0 wt % to 21 wt % and V in an amount of larger than 0 wt % to 7 wt %, and having one or more carbides selected from the group consisting of M 7 C 3  type carbide, M 6 C type carbide, M 2 C type carbide and MC type carbide precipitated and dispersed therein. 
     
     
         13 . The ferrous sintered sliding material according to  claim 3 ,
 wherein at least one phase of ferrous alloy phase and copper alloy phase of said sintered sliding material has one or more carbides selected from the group consisting of M 7 C 3  type carbide, M 6 C type carbide, M 2 C type carbide and MC type carbide and having an average grain size of 5 μm or less dispersed therein in an amount of 0.5% by volume to 30% by volume.   
     
     
         14 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said ferrous alloy powder is formed into a fine grain size of 75 μm or less.   
     
     
         15 . The ferrous sintered sliding material according to  claim 3 , containing one or more particles selected from the group consisting of graphite particle, BN particle, MoS 2  particle and WS 2  particle and having an average grain size of 0.05 mm to 1 mm dispersed therein in an amount of 1 wt % to 10 wt %. 
     
     
         16 . The ferrous sintered sliding material according to  claim 3 , having one or more structures selected from the group consisting of ferrite structure, martensite structure, bainite structure, sorbite structure and pearlite structure. 
     
     
         17 . The ferrous sintered sliding material according to  claim 3 , containing one or more elements selected from the group consisting of C, Si, Al, Mn, Ni, Cr, Mo, V, W, Co, Sn, Ca, Mg, Ag, Pb, S, P, N, B, Nb, Ti and Zr. 
     
     
         18 . The ferrous sintered sliding material according to  claim 3 ,
 wherein said mixed powder contains principle powder of, or master alloy powder containing, one or more elements selected from the group consisting of Sn in an amount of 0.1 wt % to 5 wt %, Ti in an amount of 0.1 wt % to 5 wt %, Si in an amount of 0.1 wt % to 3 wt %, P in an amount of 0.1 wt % to 1.5 wt %, Pb in an amount of 0.1 wt % to 10 wt %, Mn in an amount of 0.1 wt % to 10 wt %, Ni in an amount of 0.1 wt % to 10 wt %, Co in an amount of 0.1 wt % to 10 wt % and Ag in an amount of 1 wt % to 10 wt % further mixed therein.   
     
     
         19 . The ferrous sintered sliding material according to  claim 3 ,
 wherein a martensite phase in a ferrous alloy phase of said sintered sliding material forms a solid solution with carbon in an amount of 0.2 wt % to 0.8 wt %.   
     
     
         20 . The ferrous sintered sliding material according to  claim 3 ,
 wherein a ferrous alloy phase of said sintered sliding material forms a solid solution with carbon in an amount of 0.2 wt % to 1.2 wt %, and   a part or whole of said ferrous alloy phase is formed into a pearlite structure.   
     
     
         21 . The ferrous sintered sliding material according to  claim 3 ,
 wherein a martensite phase in said sintered sliding material has Vickers hardness Hv 450 or more, and   an amount of retained austenite phase in said martensite phase is adjusted to be 40% by volume or less.   
     
     
         22 . The ferrous sintered sliding material according to  claim 10 ,
 wherein a Fe—Cu—Al—C-based ferrous alloy phase of said Fe—Cu—C based alloy powder is composed of ferrite phase mainly and contains one or more elements of Ni in an amount of 3 wt % to 20 wt %, Mn in an amount of 3 wt % to 20 wt % and Co in an amount of 3 wt % to 20 wt %, and   said ferrite phase has Vickers hardness Hv 450 or more.   
     
     
         23 . The ferrous sintered sliding material according to  claim 3 ,
 wherein a copper alloy phase in said sintered sliding material contains Al in an amount of 5 wt % to 20 wt %, and   said copper alloy phase has Cu—Al based β-phase or γ-phase compounds.   
     
     
         24 . The ferrous sintered sliding material according to  claim 3 , having sintered pore and porous graphite in a total amount of 5% by volume to 50% by volume,
 wherein each of said sintered pore and porous graphite is filled with lubricating oil or lubricating compound.   
     
     
         25 . The ferrous sintered sliding material according to  claim 24 ,
 wherein said lubricating compound has a dropping point of 60° C. or less.   
     
     
         26 . A sliding member having a back metal and a sintered sliding body fixed to the back metal,
 wherein said sintered sliding body is a ferrous sintered sliding body containing copper in an amount of 5 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt %, and   said sintered sliding body has:   a sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %, and graphite powder, and   graphite particle dispersed therein in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume and having an average grain size of 1 μm to 50 μm.   
     
     
         27 . A sliding member having a back metal and a sintered sliding body fixed to the back metal,
 wherein said sintered sliding body is a ferrous sintered sliding body containing copper in an amount of 5 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt %, and   said sintered sliding body has:   a sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % or Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 2 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %; graphite powder; and at least one powder of copper powder and copper alloy powder, and   graphite particle dispersed therein in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume and having an average grain size of 1 μm to 50 μm.   
     
     
         28 . The sliding member according to  claim 26 ,
 wherein said sintered structure is a liquid-phase sintered structure in which copper alloy liquid phase composed of copper mainly is generated and then sintered.   
     
     
         29 . The sliding member according to  claim 26 ,
 wherein said sintered sliding body is fixed to said back metal by any method among sintering bonding, sintering infiltrating bonding, brazing, caulking, fitting, pressing, adhesion, fastening using bolt and clinching.   
     
     
         30 . The sliding member according to  claim 26 ,
 wherein said sintered sliding body is formed with recess at a sliding surface, and said recess is filled with any one of lubricating compound of lubricating oil and wax, lubricating resin, solid lubricant and lubricating compound of solid lubricant and wax.   
     
     
         31 . A coupling device comprising;
 one bearing made of the sliding member comprising the back metal and the sintered sliding body according to  claim 26 , fixed to the back metal; and   another bearing sliding with respect to the former bearing.   
     
     
         32 . The coupling device according to  claims 31 , being used as a coupling means equipped for a constructing machine, roller assembly, track link in crawler type base carrier, roller device in the crawler type base carrier, equalizer which supports a bulldozer body, suspension device of dump track, floating seal, valve guide or valve seat. 
     
     
         33 . A method for producing a ferrous sintered sliding material containing copper in an amount of 5 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt % comprising:
 a step for preparing at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %, and graphite powder;   a step for mixing the prepared powders;   a step for compacting the mixed powder to form a compact; and   a step for sintering the compact.   
     
     
         34 . A method for producing a ferrous sintered sliding material containing copper in an amount of 5 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt % comprising:
 a step for preparing at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 2 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %; graphite powder; and at least one powder of copper powder and copper alloy powder;   a step for mixing the prepared powders;   a step for compacting the mixed powder to form a compact; and   a step for sintering the compact.   
     
     
         35 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein said sintering step is a liquid-phase sintering step for generating copper alloy liquid phase composed of copper mainly and then sintering.   
     
     
         36 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein each of said Fe—Cu based ally powder and Fe—Cu—C based alloy powder contains one or more elements selected from the group consisting of C, Si, Al, Mn, Ni, Cr, Mo, V, W, Co, Sn, Ca, Mg, Ag, Pb, S, P, N, B, Nb, Ti and Zr.   
     
     
         37 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein said graphite powder has an average grain size of 1 μm to 50 μm smaller than each of said Fe—Cu based alloy powder and Fe—Cu—C based alloy powder, and said graphite powder is contained in an amount of 1 wt % to 10 wt % to said mixed powder.   
     
     
         38 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein, in said preparing step, one or more powders selected from the group consisting of BN powder, Mo powder, W powder, MnS powder, TiS powder, CaF2 powder, MoS 2  powder and WS 2  powder are additionally prepared, and,   a total content of said additionally prepared one or more powders and said graphite powder is 1 wt % to 14 wt % to said mixed powder.   
     
     
         39 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein, in said preparing step, at least one of MoS 2  powder and WS 2  powder, which are coated with graphite based material at a surface, are additionally prepared, and,   a total content of said additionally prepared powder and said graphite powder is 1 wt % to 14 wt % to said mixed powder.   
     
     
         40 . The method for producing a ferrous sintered sliding material according to  claim 33 ,
 wherein, in said preparing step, principle powder of, or master alloy powder containing, one or more elements selected from the group consisting of Sn in an amount of 0.1 wt % to 5 wt %, Ti in an amount of 0.1 wt % to 5 wt %, Si in an amount of 0.1 wt % to 3 wt %, P in an amount of 0.1 wt % to 1.5 wt %, Mn in an amount of 0.1 wt % to 10 wt %, Ni in an amount of 10 wt % or less and Co in an amount of 1 wt % to 10 wt % is additionally prepared.   
     
     
         41 . A method for producing a sliding member comprising:
 a step for dispersing a mixed powder constituting a sintered sliding body on a back metal and then liquid-phase sintering to bond said sintered sliding body on said back metal; and   a step for re-sintering said sintered sliding body by applying mechanical pressure to said sintered sliding body; and   wherein said sintered sliding body is a ferrous sintered sliding body containing copper in an amount of 10 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt %, and   said sintered sliding body has:   a liquid-phase sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 10 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 1 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %, and graphite powder, and   graphite particle dispersed in said sintered sliding body in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume and having an average grain size of 1 μm to 50 μm.   
     
     
         42 . A method for producing a sliding member comprising:
 a step for dispersing a mixed powder constituting a sintered sliding body on a back metal and then liquid-phase sintering to bond said sintered sliding body on said back metal; and a step for re-sintering said sintered sliding body by applying mechanical pressure to said sintered sliding body; and   wherein said sintered sliding body is a ferrous sintered sliding body containing copper in an amount of 10 wt % to 50 wt % and C in an amount of 1 wt % to 15 wt %, and   said sintered sliding body has:   a liquid-phase sintered structure formed by sintering a mixed powder of at least one ferrous alloy powder of Fe—Cu based alloy powder containing copper in an amount of a solid solubility limit or larger and 5 wt % to less than 50 wt % and Fe—Cu—C based alloy powder containing copper in an amount of a solid solubility limit or larger and 2 wt % to less than 50 wt % and C in an amount of larger than 0 wt % to 5 wt %; graphite powder; and at least one powder of copper powder and copper alloy powder, and   graphite particle dispersed in said sintered sliding body in an amount of 1 wt % to 14 wt % or 3% by volume to 50% by volume and having an average grain size of 1 μm to 50 cm.